Composite construction including elongated sealing and anchor members



T- 'W. HALL COMPOSITE CONSTRUCTIO July 1967 N INCLUDING ELONGATED SEALING AND ANCHOR MEMBERS Filed Sept. 10, 1964 v mvmox- @Vor /1 Haw United States Patent 3,328,934 COMPOSITE CONSTRUCTION INCLUDING ELONGATED SEALING AND ANCHOR MEMBERS Trevor W. Hall, 1371 Pierce, Birmingham, Mich. 48009 Filed Sept. 10, 1964, Ser. No. 395,498 2 Claims. (Cl. 52-597) This invention relates to composite wall panels and anchorage devices therefor, and more particularly to devices adapted to assist in securing one or more of the elements of a composite panel structure together.

In building constructions, it is often desirable to provide a panel structure, either for supporting purposes or for decorative purposes, such panel structure utilizing a cementitious material as a base and being precast or preformed before mounting on the building structure. It is oftenthe case that the outside finish of the panel base material is unsuitable as an exterior finish, either from an aesthetic sense or because of the adverse effects of weather conditions. This is particularly true of material such as foamed concrete, a material that is particularly useful as a precast curtain wall panel because of its light weight and because of the ease in precasting such material. However, the exterior finish of foam concrete is not generally suitable for decorative purposes and an exterior finish must be applied thereto.

In order to overcome these problems, it is common to provide an exterior finish of some sort on the concrete panel structure. Such exterior finish may be of a liquid material, sprayed, brushed or otherwise applied to the concrete surface, or it may take the form of a troweled material, such as plaster, applied in the usual fashion. There are other materials that may be used in layer form, such as a stone slab, any suitable stone being used so long as it may be formed in a slab orlayer configuration and which is pleasing to the aesthetic sense or performs some functional purpose.

When applying stone layers to a cementitious supporting panel, an epoxy or resin hinder or other adhesive is often used, the binder being disposed between the adjacent faces of the concrete portion and the stone slab. However, such binders and adhesives lead to numerous disadvantages. Chief among these is the possible failure of such binder due to weather conditions if the panel structure is used in an exterior location. With failure of the adhesive, the stone layer is apt to fall, creating a hazardous condition and depreciating from the aesthetic value of the structure. Furthermore, where various sections of the stone facing layer abut, it is necessary to provide some sealing means to prevent weather deterioration of the resin or epoxy binder through the joint between the slab portions. Additionally, it is difiicult to mount the stone or facing layer on the cementitious supporting layer before the curing process of the adhesive is completed, and means must be provided to secure the facing layer during such curing process.

The device in which this invention is embodied comprises, generally, an anchoring structure which additionally and mechanically secures the facing layer bonded to the cementitious layer, thus providing additional strength to the structure and more positive retention of the facing layer on the supporting layer. Such anchoring device includes an enlarged head portion receivable in suitable slots or grooves formed in the facing layers, a retainer portion which is embedded in the cementitious supporting layer and may be located therein when the supporting layer is cast or formed, and a shank port-ion connecting the enlarged head and the retainer portion. The anchoring device may be in the form of a relatively short member, and a plurality of such members located at spaced points along the length of the facing layer. The

3,328,934 Patented July 4, 1967 anchoring device may be in the form of an elongated extrusion which extends theentire length of the facing layer. Furthermore, such device may be formed of a rubher or plastic material which sealingly engages the edges of the facing layer to seal any joints and prevent the entry of water and other materials which might deteriorate the epoxy or resin binder or other adhesive between, the stone layer and the concrete supporting layer or which might have an adverse effect on either the stone or the concrete.

An anchoring device constructed and used in this fashion provides a more positive retention of the stone facing layer on the concrete supporting layer, and is adaptable to any of a series of different types of joints between the adjacent sections of the facing layer. The joints may be sealed from outside conditions to further protect the resin or epoxy binder. The anchoring devices also serve as locating means for the facing layers in the forming process of the composite panel construction.

These and other advantages will become more apparent from the following description and drawing in which:

FIGURE 1 is a cross sectional view of a portion of a composite panel structure illustrating an anchoring device mounted -in place.

FIGURE 2 is a cross sectional view similar to FIGURE 1 showing a composite panel construction and an anchoring device used in a corner joint in the facing layer.

FIGURE 3 is a perspective view of an anchoring device such as illustrated in FIGURE 1.

FIGURE 4 is a cross sectional view similar to FIG- URES l and 2 illustrating a modified form of the anchoring device in the composite panel structure.

FIGURE 5 is a cross sectional view similar to FIGURE 4 showing another modification of the anchoring device in the composite panel structure.

FIGURE 6 is a perspective view of still another modification of the anchoring device.

Referring more particularly to the drawings, FIGURE 1 best illustrates a typical cross sectional view of a com pos-ite panel construction in which the inner supporting layer, illustrated generally by the numeral 10, is formed of a cementitious material. A facing layer, illustrated generally by the numeral 12, is to be applied to the upper, or outer, surface of the supporting layer 10, and the facing layer 12 is illustrated as a series of stone slabs 14 so disposed as to completely cover the exterior surface of the supporting layer 10. Facing layer 12 is secured to the supporting layer 10 by means of an epoxy or resin binder 16 disposed between the abutting faces of the two layer structures.

In order to additionally and mechanically secure the facing layer 12 to the supporting layer 10, an anchoring device, illustrated generally by the numeral 18, is pro vided. The members 14 of the facing layer 12 are disposed in edge-to-edge relation with a slight space therebetween. In each edge surface 20 of the members 14, a slot or rabbet 22 is formed extending inwardly thereof in a direction generally parallel to the surface of the supporting layer 10". Such slot 22 may be formed in any convenient manner, for example, by a saw cut running the length of the edge of member 14.

Anchoring device 18 includes an enlarged head 24 having a thickness substantially the same as the width of the slots 22 in the members 14. Head 24 extends into both slots 22 of the adjacent members 14 and bridges bedded in the cementitious supporting layer when the layer 10 is formed. It is apparent that the enlarged head 24, hearing against the members 14 and held in place in the supporting layer 10, aids in maintaining the members 14 on the supporting layer 10 along with the binder or adhesive 16.

Where the facing layer 12 is mounted at a corner of the supporting layer 10, the members 14 are generally beveled, as at 30 in FIGURE 2, requiring a modified form of the anchoring device. As illustrated in FIGURE 2, anchoring device 32 is provided with an angular head 34 including legs 36 extending into slots 32 formed in a direction parallel to the surface of the supporting layer 10. A shank portion 38, terminating in angularly disposed legs 40, is embedded in the supporting layer 10, and serves to clamp or secure the facing members 14 against the surfaces of the supporting layer 10.

The anchoring device 18 or 32, of FIGURES l and 2 respectively, may :be formed in long lengths of a suitable metallic or plastic material to extend substantially the length of the members 14. Alternatively, the anchoring devices 18 and 32 may be of short lengths and a series of such devices spaced at proper points along the length of the members 14. The particular choice depends upon the design characteristics of the composite panel construction and the desired aesthetic effect of the exterior of the panel. Should the anchoring devices 18 or 32 be formed of long lengths of suitable material, they may be extruded, injection molded or otherwise formed in the most economical and efiicient manner possible.

A modified form of the anchoring device is illustrated in FIGURE 4 wherein the composite panel includes the cementitious supporting layer 10 to which the face layer 12 is to be secured, as by the resin or epoxy binder 16. As illustrated in FIGURE 4, the face layer 12 includes members 42 secured at a corner of the supporting layer 10. Members 42 are beveled at 44 to receive an enlarged head 46 of the anchoring device, illustrated generally by the numeral 48. Head 46 is provided with undersurfaces 50 to cooperate with the bevels 44, and an outer rounded surface or the like 52 closes the space between the members 42. Extending inwardly from the head 46 is a shank portion 54, terminating in an enlargement 56 within the cementitious supporting layer 10. The enlargement 56 and shank 54 are embedded in the supporting layer 10 when the layer is cast or formed. The anchoring device 48 is formed of a rubber or plastic material which sealingly engages the surfaces 44 and prevents any moisture or the like from entering the joint between the members 42 and thus into the resin binder 16 or the supporting layer 10. The outer surface 52 of the head 46 may be formed in any suitable shape in keeping with the desired aesthetic effect.

Another modification of an anchoring device somewhat similar to that illustrated in FIGURE 4 is shown in FIG- URE 5. The supporting layer 10 is to have secured thereto the face layer 12, including the members 42. Members 42 are disposed in aligned edge-to-edge relation on the supporting panel 10 with a slight space betwen their adjacent edges. Formed in the surface of the members 42 adjacent the closely disposed edges are grooves 58 which receive the enlarged head 60 of the anchoring device 62, illustrated generally by the numeral 62. The enlarged head 60 fills the grooves 48 and bridges the gap between the two members 42. Extending inwardly from enlarged head 60 is a shank portion 64, terminating in an enlargement 66 embedded within the supporting layer 10. Anchoring device 62 is formed of a rubber or plastic material to sealingly engage the members 42 and to prevent any moisture or the like from entering the composite panel structure.

The anchoring devices 48 and 62, as illustrated in FIG- URES 4 and 5, respectively, may also be formed in long lengths extending the dimension of the members 42. Alternatively, the devices 48 and 62 may be relatively short lengths and a series of such devices spaced along the joints between the members 42 as desired. Again, the question of which type of anchoring device is best suited depends upon the structural qualifications as well as the aesthetic desires.

A still further modification of the anchoring device is illustarted in FIGURE 6. In this embodiment of the invention, the anchoring device 68 is formed of a suitable wire material to provide an enlarged triangular head portion 70, connected by shank legs 72 to angularly directed leg members 74. Anchoring device 68 is used in the same fashion as the anchoring devices illustrated in FIGURES 1 through 5, the enlarged head being receivable in the slots formed in the edges of the facing layer or in the grooves or bevels formed in the surfaces thereof. The shank portion 72 and angularly outwardly directed legs 74 are embedded in the cementitious supporting layer to assist the binder or adhesive in securing the facing layer to the supporting layer.

The composite panel structure may be formed in several ways. One of these is to lay the facing layer members in a form with the anchoring devices properly disposed in the slots or grooves and extending outwardly therefrom. A suitable binder material coats the exposed surface of the face layer members and the cementitious supporting layer is then poured and allowed to cure to its proper form. By so doing, the shank portion and retaining portion of the anchoring device will be firmly embedded in the cement supporting layer. The entire unit or assembly may then be mounted in the building construction.

Alternatively, the cementitious supporting layer may be first formed with the anchoring devices extending outwardly therefrom. After the supporting layer has been allowed to cure and harden, the upper surface is coated with the resin or epoxy binder material and the facing layer member slid into place under the enlarged heads of the anchoring devices. Once the facing layer members are properly located by the anchoring devices, the epoxy or resin binder material is allowed to cure to additionally secure the facing layer to the supporting layer.

It is also possible that the cementitious supporting layer may be formed with the anchoring devices extending therefrom and then mounted in place in the building construction. At this point, the facing layer members may be slid into place under the enlarged heads of the anchoring devices where the epoxy or resin binder material is allowed to cure to maintain the firm contact required.

Thus, an anchoring device is provided which more positively secures a stone facing layer to a cementitious supporting layer and assists the epoxy or resin binder often used in such installations. The anchoring device is extremely simple to manufacture and install, and when mounted in place in the composite panel structure combines secure retention with a pleasant appearance. At the same time, the anchoring devices may seal the joints between various facing layer members to prevent the entrance of moisture and the like which might otherwise destroy the panel construction.

Numerous alternations, changes, and modifications in the anchoring devices and in the panel construction will occur to those having skill in the art after having having had reference to the foregoing description and drawing. However, it is not intended to limit the scope of the invention by the foregoing description and drawing, but by the scope of the appended claims in which:

I claim:

1. A composite panel construction comprising:

a cementitious supporting layer;

a facing layer including a pair of members bonded to said supporting layer and disposed in slightly spaced and aligned edge-to-edge relation, each of said members having a slot formed along the edge thereof and extending inwardly of said member in a direction parallel to said supporting layer;

and an anchoring device for additionally and mechanically securing said members to said supporting layer, said device having an enlarged head extending into said slots and being in tight fitting and abutting engagement with the surfaces of said members on each side of said slots to prevent entry of foreign materials to said supporting layer and to the bond between said members and said supporting layer, said anchorage device having a retaining portion embedded in said supporting layer and a shank portion connecting said head portion and said retaining portions, said retaining portion including a pair of angularly outwardly directed legs, and said shank portion being disposed in the space between said members;

said anchoring device extending substantially the length of said members.

2. A composite panel construction comprising:

a cementitious supporting layer;

a facing layer including a pair of members bonded to said supporting layer and disposed in slightly spaced edge-to-edge aligned relation, each of said members having a portion of reduced thickness adjacent said edge;

and an anchoring device for additionally and mechanically secured said members to said supporting layer, said device having an enlarged head extending across said portions of said members of reduced thickness, a shank portion extending toward said supporting layer from said head portion and filling the space be- References Cited UNITED STATES PATENTS 10/1883 Graham 52509 X 5/1936- Maul 52--254 9/1938 Arand 52-391 11/1938 Stewart 52396 2/ 1941 Batcheller 52597 X 5/1943 Putnam 52597 X 1/1962 Murphy 52509 3/1966 Fitzgerald 52309 FOREIGN PATENTS 11/ 1957 'Belgium. 2/ 1951 France. 4/ 1962 France. 4/ 1924 Switzerland.

FRANK L. ABBOTT, Primary Examiner. A. C. PERHAM, Assistant Examiner. 

1. A COMPOSITE PANEL CONSTRUCTION COMPRISING: A CEMENTITIOUS SUPPORTING LAYER; A FACING LAYER INCLUDING A PAIR OF MEMBERS BONDED TO SAID SUPPORTING LAYER AND DISPOSED IN SLIGHTLY SPACED AND ALIGNED EDGE-TO-EDGE RELATION, EACH OF SAID MEMBERS HAVING A SLOT FORMED ALONG THE EDGE THEREOF AND EXTENDING INWARDLY OF SAID MEMBER IN A DIRECTION PARALLEL TO SAID SUPPORTING LAYER; AND AN ANCHORING DEVICE FOR ADDITIONALLY AND MECHANICALLY SECURING SAID MEMBERS TO SAID SUPPORTING LAYER, SAID DEVICE HAVING AN ENLARGED HEAD EXTENDING INTO SAID SLOTS AND BEING IN TIGHT FITTING AND ABUTTING ENGAGEMENT WITH THE SURFACES OF SAID MEMBERS ON EACH SIDE OF SAID SLOTS TO PREVENT ENTRY OF FOREIGN MATERIALS TO SAID SUPPORTING LAYER AND TO THE BOND BETWEEN SAID MEMBERS AND SAID SUPPORT- 